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    17ABSTRACT A method of cutting a profile in a cylinder surface. The method includes simultaneouslyinterpolating an axial portion of the cylindrical surface using a cutting tool to form a profilehaving a plurality of annular grooves and a pocket having a radius larger than the cylindrical surface prior to the interpolating step. To be published with Fig 1A.
    公开号:SE1450696A1
    申请号:SE1450696
    申请日:2014-06-09
    公开日:2014-12-11
    发明作者:Rodney G Whitbeck；David Alan Stephenson；Keith Raymond Bartle；David Garrett Coffman
    申请人:Ford Global Tech Llc；
    IPC主号:
    专利说明:

    [1] [0001] The present invention relates to a cylindrical surface cutting tool and process.BACKGROUND[0002] Automotive engine blocks include a number of cylindrical engine bores. The inner surface of each engine bore is machined so that the surface is suitable for use in auto-motive applications, e.g., exhibits suitable wear resistance and strength. The machiningprocess may include roughening the inner surface and subsequently applying a metalliccoating to the roughened surface and subsequently honing the metallic coating to obtain afinished inner surface. Various surface roughening techniques are known in the art, but have suffered from one or more drawbacks or disadvantages.SUMMARY
    [3] [0003] A method of cutting a profile in a cylinder surface is disclosed. The methodincludes simultaneously interpolating an axial portion ofthe cylindrical surface using a cuttingtool to form a profile having a plurality of annular grooves and a pocket having a radius larger than the cylindrical surface prior to the interpolating step.
    [4] [0004] The flat peaks may be formed between adjacent grooves, and the method mayfurther include deforming each flat peak to form an undercut region. The method may furtherinclude forming the cylindrical surface by pre-boring an unhoned cylindrical surface. Thecylindrical surface may be an aluminum or magnesium alloy. The cutting tool may include a cylindrical cutting body having cutting elements and may be mounted in a spindle. ln one embodiment, the simultaneously interpolating step includes rotating the cylindrical cutting body relative to the spindle at a rotation speed. The rotation speed may be at least 4,500 rpm.
    [6] [0006] A method of cutting a profile in an inner surface of a cylindrical bore is disclosed.The inner surface includes an axial travel area and an axial non-travel area. The methodincludes interpolating the axial non-travel area using a cutting tool to form a profile having aplurality of annular grooves. ln one or more embodiments, the nominal diameter of the axialtravel area is greater than that of the axial non-travel area. ln one or more embodiments, theaxial non-travel area includes two discontinuous axial widths of the cylindrical bore, and theaxial travel area extends therebetween. The aspect ratio of the depth ofthe annular grooves to the width ofthe annual grooves may be 0.5 or less. The plurality of annular grooves may be a plurality of rectangular annular grooves.
    [7] [0007] A method of cutting a profile in a cylinder bore surface is disclosed. The methodincludes forming a profile having a plurality of annular grooves and a plurality of peaks there-between, and cutting an upper portion ofthe plurality of annular peaks to reduce the height of the annular peaks.BRIEF DESCRIPTION OF THE DRAWINGS
    [8] [0008] Figure 1A depicts a top view of a joint or deck face of an exemplary engine block of an internal combustion engine;
    [9] [0009] Figure 1B depicts an isolated, cross-sectional view of a cylinder bore taken along line 1B-1B of Figure 1A;
    [10] [0010] Figure 2A depicts a pre-boring step in which an unprocessed cylinder bore inner surface is bored to a diameter;
    [11] [0011] Figure 2B depicts an interpolating step in which a travel area is machined using a cutting tool to produce a recessed inner surface with a pocket and annular surface grooves;
    [12] [0012] Figure 2C depicts a deforming step in which flat peaks between adjacent grooves are deformed to obtain deformed peaks; 3[0013] Figure 2D depicts an interpolating step in which one or more of the non-travel areas are machined using a cutting tool to form annular grooves;
    [14] [0014] Figure 2E shows a magnified, schematic view of annular grooves formed in the non-travel areas of an engine bore;
    [15] [0015] Figure 3A depicts a perspective view of a cutting tool according to one embodiment;
    [16] [0016] Figure 3B depicts a top view of cutting tool showing a top axial row of cuttingelements;[0017] Figures 3C, 3D and 3E depict cross-sectional, schematic views of first and second groove cutting elements and pocket cutting elements taken along lines 3C-3C, 3D-3D and 3E-3E of Figure 3A, respectively;
    [18] [0018] Figure 3F shows a cylindrical shank for mounting a cutting tool in a tool holder according to one embodiment;
    [19] [0019] Figure 4A is a schematic, top view of a cylinder bore according to one embodiment;
    [20] [0020] Figure 4B is a schematic, side view of the cylinder bore of Figure 4B according to one embodiment;
    [21] [0021] Figure 5 shows an exploded, fragmented view ofthe inner surface ofthe cylinder bore before, during and after an interpolating step;
    [22] [0022] Figure 6A, 6B and 6C illustrate a swiper tool according to one embodiment; and
    [23] [0023] Figure 7 illustrates a magnified, cross-sectional view of the inner surface of a cylinder bore.DETAILED DESCRIPTION
    [24] [0024] Reference will now be made in detail to embodiments known to the inventors.However, it should be understood that disclosed embodiments are merely exemplary of the present invention which may be embodied in various and alternative forms. Therefore, 4specific details disclosed herein are not to be interpreted as limiting, rather merely asrepresentative bases for teaching one skilled in the art to variously employ the present invention.
    [25] [0025] Except where expressly indicated, all numerical quantities in this descriptionindicating amounts of material are to be understood as modified by the word ”about” in describing the broadest scope of the present invention.
    [26] [0026] Automotive engine blocks include a number of cylindrical engine bores. Theinner surface of each engine bore is machined so that the surface is suitable for use in auto-motive applications, e.g., exhibits suitable wear resistance and strength. The machiningprocess may include roughening the inner surface and subsequently applying a metalliccoating to the roughened surface and subsequently honing the metallic coating to obtain afinished inner surface with requisite strength and wear resistance. Alternatively, a liner material having requisite strength and wear resistance characteristics may be applied to the unfinished inner surface of the engine bore.
    [27] [0027] Embodiments disclosed herein provide cutting tools and processes forroughening the inner surface of cylindrical bores, e.g., engine bores, to enhance the adhesionand bonding of a subsequently applied metallic coating, e.g., thermal spray coating, onto theinner surface. Accordingly, the finished inner surface may have enhanced strength and wear resistance.
    [28] [0028] Figure 1A depicts a top view of a joint face of an exemplary engine block 100 ofan internal combustion engine. The engine block includes cylinder bores 102. Figure 1B depictsan isolated, cross-sectional view of cylinder bore 102 taken along line 1B-1B of Figure 1A.Cylinder bore 102 includes an inner surface portion 104, which may be formed of a metalmaterial, such as, but not limited to, aluminum, magnesium or iron, or an alloy thereof, orsteel. ln certain applications, aluminum or magnesium alloy may be utilized because of theirrelatively light weight compared to steel or iron. The relatively light weight aluminum or magnesium alloy materials may permit a reduction in engine size and weight, which may improve engine power output and fuel economy. 5[0029] Figures 2A, 2B, 2C, 2D and 2E depict cross-sectional views of a cylinder bore innersurface relating to steps of a process for applying a profile to the inner surface of the cylinderbore. Figure 2A depicts a pre-boring step in which an unprocessed cylinder bore inner surface200 is bored to a diameter that is less than the diameter of the finished, e.g., honed, diameterof the inner surface. ln some variations, the difference in diameter is 150 to 250 microns (um). ln other variations, the difference in diameter is 175 to 225 microns. ln one variation, the difference in diameter is 200 microns.
    [30] [0030] Figure 2B depicts an interpolating step in which a travel area 202 is machinedinto the pre-bored inner surface 200 using a cutting tool. lnterpolation-based roughening canbe accomplished with a cutting tool suitable for cylinder bores of varying diameter. Thecutting tool can be used to roughen only a selected area ofthe bore, such as the ring travelarea ofthe bore. Roughening only the ring travel portion of the bore may reduce coating cycle time, material consumption, honing time and overspray ofthe crank case.
    [31] [0031] The length of the travel area corresponds to the distance in which a pistontravels within the engine bore. ln some variations, the length oftravel area 202 is 90 to 150millimeters. ln one variation, the length of travel area 202 is 117 millimeters. The travel areasurface is manufactured to resist wear caused by piston travel. The cutting tool forms annulargrooves 204 (as shown in magnified area 208 of Figure 2B) and a pocket 206 into the travelarea 202. lt should be understood that the number of grooves shown in magnified area 208are simply exemplary. Dimension 210 shows the depth of pocket 206. Dimension 212 showsthe depth of annular grooves 204. ln some variations, the groove depth is 100 to 140 microns. ln another variation, the groove depth is 120 microns. ln some variations, the pocket depth is 200 to 300 microns. ln another variation, the pocket depth is 250 microns.
    [32] [0032] The pre-bored inner surface 200 also includes non-travel portions 214 and 216.These areas are outside the axial travel distance of the piston. Dimensions 218 and 220 showthe length of non-travel portions 214 and 216. ln some variations, the length of non-travelarea 214 is 2 to 7 millimeters. ln one variation, the length of non-travel area 214 is 3.5 milli-meters. ln some variations, the length of non-travel area 216 is 5 to 25 millimeters. ln one variation, the length of non-travel area 216 is 17 millimeters. The cutting tool and the inter- polating step are described in greater detail below. 6[0033] Figure 2C depicts a deforming step in which the flat peaks between adjacentgrooves 204 are deformed to obtain deformed peaks 222 in which each peak 222 includes apair of undercuts 224, as shown in magnified area 226 of Figure 2C. lt should be understoodthat the number of deformed peaks shown in magnified area 226 are simply exemplary. The deforming step may be carried out using a swiping tool. The swiping tool and the deforming step are described in greater detail below.
    [34] [0034] Figure 2D depicts an interpolating step in which one or more of the non-travelareas 214 and 216 are machined using a cutting tool to form annular grooves 228, as shown inmagnified area 230 of Figure 2E. Flat peaks 232 extend between annular grooves 228. ltshould be understood that the number of grooves shown in magnified area 230 are simplyexemplary. ln one embodiment, the grooves form a square wave shape of a uniformdimension. ln some variations, the dimension is 25 to 100 microns. ln one variation, the dimension is 50 microns. As described in more detail below, the cutting tool may form a profile ofgrooves within one or more ofthe non-travel areas 214 and 216.
    [35] [0035] Figure 3A depicts a perspective view of a cutting tool 300 according to oneembodiment. Cutting tool 300 includes a cylindrical body 302 and first, second, third andfourth axial rows 304, 306, 308 and 310 of cutting elements. Cylindrical body 302 may beformed of steel or cemented tungsten carbide. The cutting elements may be formed of acutting tool material suitable for machining aluminum or magnesium alloy. The considerationsfor selecting such materials include without limitation chemical compatibility and/or hardness.Non-limiting examples of such materials include, without limitation, high speed steel, sinteredtungsten carbide or polycrystalline diamond. Each axial row 304, 306, 308 and 310 includes 6cutting elements. As shown in Figure 3A, the 6 cutting elements are equally radially spacedapart from adjacent cutting elements. ln other words, the six cutting elements are located at0, 60, 120, 180, 240, and 300 degrees around the circumference of the cylindrical body 302.While 6 cutting elements are shown in Figure 3A, any number of cutting elements may be used according to one or more embodiments. ln certain variations, 2 to 24 cutting elements are utilized.
    [36] [0036] Figure 3B depicts a top view of cutting tool 300 showing the first axial row 304 of cutting elements. As shown in Figure 3B, the 0 degree cutting element includes a cutting 7 surface 312 and a relief surface 314. The other degree cutting elements include similar cuttingand relief surfaces. ln the embodiment shown, each ofthe cutting elements is one of threetypes of cutting elements, i.e., a first type of groove cutting element (G1), a second type ofgroove cutting element (G2) and a pocket cutting element (P). ln the embodiment shown inFigure 3B, the 60 and 240 degree cutting elements are the first type of groove cuttingelement; the 120 and 300 degree cutting elements are the second type ofgroove cuttingelement; and the 0 and 180 degree cutting elements are the pocket cutting element.Accordingly, the sequence of cutting elements from 0 to 300 degrees is G1, G2, P, G1, G2 andP, as shown in Figure 3B. However, it shall be understood that any sequence of cuttingelements is within the scope of one or more embodiments. ln some variations, the sequence isG1, P, G2, G1, P and G2 or P, G1, G1, P, G2 and G2. ln the embodiment shown, two groovecutting elements are necessary due to the width and number of valleys between peaks, whichexceed the number and widths which can be cut with one element. For other groovegeometries, one or three groove cutting elements may be used. The sequence of cutting is not significant as long as all utilized elements are in the axial row.
    [37] [0037] ln some variations, there is at least one of G1 and G2 and at least one of P. Asshown in Figure 3A, the cutting elements in each row are offset or staggered circumferentiallyfrom one another between each row, e.g., each cutting element ofthe 0, 60, 120, 180, 240and 300 degree cutting elements is staggered by 60 degrees in adjacent rows. The staggeringimproves the lifetime of the cutting tool by smoothing out the initial cutting of the innersurface profile. lf the cutting elements are aligned between adjacent rows, more force would be necessary to initiate the cutting operation, and may cause more wear on the cutting elements or deflection and vibration of the tool.
    [38] [0038] Figures 3C, 3D and 3E depict cross-sectional, schematic views of G1, G2 and Pcutting elements taken along lines 3C-3C, 3D-3D and 3E-3E of Figure 3B, respectively.Referring to Figure 3C, a G1 cutting element 318 is shown having cutting surface 320, reliefsurface 322 and locating surface 324. The cutting surface 320 schematically includes a numberof teeth 326. lt should be understood that the number of teeth shown are simply exemplary.ln certain variations, the number of teeth is 1 to 2 per millimeter of axial length. ln one variation, the number of teeth is 1.25 teeth per axial length. Each tooth is rectangular in shape, although other shapes, e.g., square shapes, are contemplated by one or more 8 embodiments. Each tooth has a top surface 328 and side surfaces 330. As shown in Figure 3C,the length of top surface 328 is 250 microns and the length of side surfaces 330 is 300microns. ln other variations, the length of the top surface is 200 to 400 microns and the lengthof the side surfaces is 200 to 500 microns. Flat valleys 358 extend between adjacent teeth 326.As shown in Figure 3C, the width of the valley 358 is 550 microns. ln other variations, thewidth of the valley is 450 to 1000 microns. Cutting element 318 also includes a chamfer 334. lnthe embodiment shown, chamfer 334 is at a 15 degree angle. This chamfer provides stressrelief and ease of mounting of the cutting elements. ln the embodiment shown, the cuttingelements are replaceable brazed polycrystalline diamond elements. ln other embodiments, replaceable tungsten carbide elements mounted in adjustable cartridges may be used.
    [39] [0039] Referring to Figure 3D, a G2 cutting element 336 is shown having a cuttingsurface 338, a relief surface 340 and a locating surface 342. The cutting surface 338schematically includes a number of teeth 344. lt should be understood that the number ofteeth shown are simply exemplary. ln certain variations, the number of teeth is 1 to 2 teethper millimeter of axial length. ln one variation, the number of teeth is 1.25 per millimeter ofaxial length. Each tooth is rectangular in shape, although other shapes, e.g., square shapes,are contemplated by one or more embodiments. Each tooth has a top surface 346 and sidesurfaces 348. As shown in Figure 3D, the length of top surface 346 is 250 microns and thelength of side surfaces 348 is 300 microns. ln other variations, the length of the top surface is200 to 400 microns and the length of the side surfaces is 200 to 500 microns. Tooth 350, whichis closest to relief surface 340, has an outermost side wall that is offset from relief surface 340.As shown in Figure 3D, the offset is 400 microns. ln other variations, the offset may be 0 to500 microns. Flat valleys 358 extend between adjacent teeth 344. As shown in Figure 3D, thewidth of the valley 358 is 550 microns. ln other variations, the width of the valley is 400 to1000 microns. Cutting element 336 also includes a chamfer 352. ln the embodiment shown,chamfer 352 is at a 15 degree angle. This chamfer provides stress relief and ease of mountingof the cutting elements. ln the embodiment shown, the cutting elements are replaceable brazed polycrystalline diamond elements. ln other embodiments, replaceable tungsten carbide elements mounted in adjustable cartridges may be used.
    [40] [0040] ln the embodiment shown, the arrangement of teeth on the G1 and G2 cutting elements are dimensioned differently. Regarding G1 shown in Figure 3C, tooth 332, which is 9 closest to leading edge 322, has an outermost side wall that is flush with relief surface 322.Regarding G2 shown in Figure 3D, tooth 350, which is closest to leading edge 340, has anoutermost side wall that is offset from relief surface 340. As shown in Figure 3D, the offset is400 microns. ln other variations, the offset may be 0 to 500 microns. Accordingly, there is a400 micron offset between the relief edge tooth of G1 and relief edge tooth of G2. The reliefsurface facing side of the sixth tooth 354 of G1 cutting element 318 and the relief surfacefacing side of the fifth tooth 356 of G2 cutting element 336 are offset from each other by 550microns. These differing dimensions are utilized so that within each row of cutting elements,the G1 and G2 cutting elements can be axially offset from each other. For example, the axialoffset may be 550 microns. ln this embodiment, this allows the edges to cut two separate rows ofgrooves, one by each offset element, with acceptable stress on the teeth.
    [41] [0041] Referring to Figure 3E, a P cutting element 362 is shown having a cutting surface364, relief surface 366 and a locating surface 368. Cutting surface 364 is flat or generally flat,and has no teeth, in contrast to the cutting surfaces ofthe G1 and G2 cutting elements, whichare shown in phantom. The teeth shown in phantom line in Figure 3E indicates the toothgeometry of the G1 and/or G2 cutting elements and how the cutting surface 364 is radiallyoffset away from the tooth top surfaces 328 and 346. The P cutting element 362 removes aportion ofthe peaks between the grooves and creates the pocket. The amount of radial offsetcontrols the depth ofthe grooves cut in the bottom of the pocket depicted in Figure 2B. ln theillustrated embodiment, the dimension 120 microns in Figure 3E is the depth of the groovesthat are cut when the G1, G2 and P elements are used in combination. The dimension of 50.06 millimeters is the diameter of the cutting tool measured to the top surfaces (minimum diameter) of the teeth that are formed.
    [42] [0042] Figure 3F shows a cylindrical shank 380 for mounting cutting tool 300 into a toolholder for mounting in a machine spindle. ln other embodiments, the shank may be replaced by a direct spindle connection, such as a CAT-V or HSK taper connection.
    [43] [0043] Having described the structure of cutting tool 300 according to one embodiment,the following describes the use of cutting tool 300 to machine a profile into an inner surface ofa cylinder bore. Figure 4A is a schematic, top view of a cylinder bore 400 according to one embodiment. Figure 4B is a schematic, side view of cylinder bore 400 according to one embodiment. As shown in Figure 4A, cutting tool 300 is mounted in a machine tool spindlewith an axis of rotation AT parallel to the cylinder bore axis AB. The tool axis AT is offset fromthe bore axis AB. The spindle may be either a box or motorized spindle. The tool rotates in thespindle about its own axis AT at an angular speed 01 and precesses around the bore axis AB atangular speed QZ. This precession is referred to as circular interpolation. The interpolatingmovement permits the formation of a pocket and annular, parallel grooves within the inner surface of a cylinder bore.
    [44] [0044] ln one embodiment, the aspect ratio ofthe diameter ofthe cutting tool DT to theinner diameter of the bore DB is considered. ln certain variations, the inner diameter issubstantially greater than the cutting tool diameter. ln certain variations, the cutting tooldiameter is 40 to 60 millimeters. ln certain variations, the inner diameter of the cylinder boreis 70 to 150 millimeters. Given this dimensional difference, this cutting tool may be utilized with a significant variation in bore diameter. ln other words, use of the cutting tools of one or more embodiments does not require separate tooling for each bore diameter.
    [45] [0045] Regarding the pre-boring step of Figure 2A identified above, a boring bar (notshown) can be attached to a machine spindle to bore a diameter that is less than the diameterof the finished diameter ofthe inner surface. ln certain variations, the feed rate, i.e., the ratein which the boring bar is fed radially outward into the inner surface, ofthe spindle is 0.1 to0.3 mm/rev. ln one or more embodiments, the spindle is telescoping. ln other embodiments,the spindle may be fixed and the bore may move. ln another variation, the feed rate is 0.2 mm/rev. ln certain variations, the rotational speed ofthe boring bar is 1000 to 3000 rpms. ln another variation, the rotational speed of the boring bar is 2000 rpms.
    [46] [0046] Regarding the interpolating step of Figure 2B identified above, the cutting tool300 is used to machine a profile into the inner surface of cylinder bore 400. ln certainvariations, the interpolating feed rate (radially outward) of the spindle during this step is 0.1 to0.3 mm/rev. ln another variation, the feed rate is 0.2 mm/rev. ln certain variations, the rotational speed of cutting tool 300 is 3000 to 10000 rpms. ln another variation, the rotational speed of cutting tool 300 is 6000 rpms.
    [47] [0047] As described above, cutting tool 300 includes cylindrical body 302 that includes four rows of cutting elements. According to this embodiment, the axial length of the cut is 35 11 mm. Therefore, ifthe length of the travel area is 105 mm, three axial steps are used tocomplete the interpolating of the travel area. ln other words, the axial position of the spindleis set at an upper, middle and lower position before rotating the cutting tool at each of thepositions. While 4 cutting element rows are shown in one embodiment, it is understood thatadditional rows may be utilized. For example, 6 rows may be used to cut a similar travel areain 2 axial steps instead of 3. Further, 12 rows may be used to cut a similar travel area in 1 axial step.
    [48] [0048] Moving to Figure 4B, a fragmented portion of cylindrical body 302 of cutting tool300 and cutting elements from axial rows 304, 306, 308 and 310 are schematically shown inoverlapping relationship. As described above and shown in this Figure 4B, there are overlaps406, 408 and 410 between adjacent cutting element rows. This overlap helps provide uniform and consistent profile cutting in boundary regions.
    [49] [0049] Figure 5 shows an exploded, fragmented view of the inner surface 500 of thecylinder bore before, during and after the interpolating step. The cutting tool 300 is fedradially outward into the surface of the cylinder bore at a rate of 0.2 mm per revolution. Whilethe cutting tool 300 is being fed into the inner surface, it is rotating at a speed of 6000 rpms.The P pocket cutting elements cut pocket 502 into the inner surface 500. The height of thepocket is H and the width is WV. The H value corresponds to the axial offset between thevalleys 358 of G1 and G2 cutting elements 318 and 336 and the cutting surface 364 of Pcutting element 362. ln a non-limiting, specific example, the offset is 250 microns. Therefore,H is 250 microns. The WV value corresponds to the length of the tooth upper surfaces 328 and346, 356 ofthe G1 and G2 cutting elements 318 and 336. ln the non-limiting, specific example set forth above, the tooth upper surfaces have a length of 250 microns. Accordingly, WV is 250 microns.
    [50] [0050] The groove cutting elements G1 and G2 remove material 504 to create peaks506. The height of these peaks is h and the width is Wp. ln the non-limiting, specific exampleshown, Wp is 150 microns. The h value is determined by the radial offset between the top ofgroove cutting elements G1 and G2 and the pocket cutting element P. ln the non-limiting, specific example set forth above, this offset is 120 microns. Therefore, h is 120 microns. The WV value corresponds to the length of the flat valleys between groove-cutting teeth top 12 surfaces. ln the non-limiting, specific example set forth above, the valley length is 250 microns.
    [51] [0051] Regarding the deforming step of Figure 2C above, a swiper tool is used to swipeselective area flat peaks between grooves. As used herein in certain embodiments, ”swipe” isone form of deforming the selective areas. ln one embodiment, deforming does not includecutting or grinding the selective area. These types of processes typically include complete or atleast partial material removal. lt should be understood that other deforming processes may beutilized in this step. Non-limiting examples of other secondary processes include rollerburnishing, diamond knurling or a smearing process in which the flank of the pocket cuttingtool is used as a wiper insert. ln certain variations, the feed rate of the spindle during this stepis 0.1 to 0.3 mm/rev. ln another variation, the feed rate is 0.2 mm/rev. ln certain variations, the rotational speed of swiper tool 300 is 5000 to 7000 rpms. ln another variation, the rotational speed of a swiper tool is 6000 rpms.
    [52] [0052] Figure 6A, 6B and 6C illustrate a swiper tool 600 according to one embodiment.Figure 6A shows a top view of swiper tool 600. Figure 6B shows a magnified view of region 602of swiper tool 600. Figure 6C shows a side view of swiper tool 600, including cylindrical shank604. Swiper tool 600 includes 4 swiping projections 606, 608, 610 and 612. Each swipingprojection 606, 608, 610 and 612 project outward from the center 614 of swiper tool 600. lnone embodiment, the swiper tool has the same diameter as the cutting tool, and the swiperelements have the same axial length as the cutting elements, so that the swiping tool and thecutting tool may be run over the same tool path to simplify programming and reduce motionerrors. Each swiping projection includes relief surface 616, a back surface 618, and a rakesurface 620. A chamfer 622 extends between rake surface 620 and relief surface 616. Thechamfer or like edge preparation, such as a hone, is used to ensure that the tool deforms the peaks instead of cutting them. ln one variation, the angle ofthe chamfer 622 relative to the landing surface 616 is 15 degrees. ln other variations, the angle is 10 to 20 degrees, or a hone 13with a radius of 25 to 100 microns. ln one embodiment, the angle between the rake surface and the relief surface of adjacent swiping projections is 110 degrees.
    [53] [0053] The swiping tool 602 is dull enough that it does not cut into the inner surface ofthe cylinder bore. lnstead, the swiping tool 602 mechanically deforms grooves formed in theinner surface of the cylinder bore. I/loving back to Figure 5, the swiping tool 600, usedaccording to the methods identified above, created undercuts 508 and elongates uppersurface 510. As shown in Figure 5, the difference between h (the height ofthe non-deformedpeak) and the height ofthe deformed peak is Ah. ln one variation, Ah is 10 microns, while in other variations, Ah may be 5 to 60 microns. The undercuts increase the adhesion of a sub- sequent thermal spray coating onto the roughened inner surface of the cylinder bore.
    [54] [0054] The machined surface after the pocket grooving step and the swiping step hasone or more advantages over other roughening processes. First, adhesion strength of themetal spray may be improved by using the swiping step instead of other secondary processes,such as diamond knurling, roller burnishing. The adhesion strength was tested using a pulltest. The adhesion strength may be in the range of 40 to 70 I/|Pa. ln other variations, theadhesion strength may be 50 to 60 I/|Pa. Compared to the adhesion strength of a diamondknurling process, the adhesion strength of swiping is at least 20% higher. Further, theApplicants have recognized that adhesion is independent of profile depth ofthe grooves afterthe first processing step. This may be advantageous for at least two reasons. The swiping toolcuts relatively lower profile depths compared to conventional processes, such as diamondknurling, roller burnishing. ln certain variations, the reduction in profile depth is 30 to 40%.Accordingly, less metal spray material is necessary to fill the profile while not compromisingadhesion strength. Also, any variation in the depth of the grooves does not affect the adhesionstrength, which makes the swiping step more robust than conventional processes. As another benefit of one or more embodiments, the swiping tool can be operated at much higher operational speeds than other processes, such as roller burnishing.
    [55] [0055] Regarding the interpolating step of Figure 2D above, the cutting tool 300 is usedto machine non-travel areas 214 and 216 to form annular grooves. ln certain variations, the feed rate of the spindle during this step is 0.1 to 0.3 mm/rev. ln another variation, the feed 14rate is 0.2 mm/rev. ln certain variations, the rotational speed of cutting tool 300 is 3000 to 10000 rpms. ln another variation, the rotational speed of a cutting tool is 6000 rpms.
    [56] [0056] These non-travel areas do not require a subsequent metal spray. However, atorch for metal spraying typically stays on throughout the spray process. lf these non-ringtravel areas are not roughened, then spray metal that is inadvertently sprayed on these areasdo not adhere, causing delamination. This delamination may fall into the bore during honingand become entrapped between the honing stones and bore walls, causing unacceptablescratching. The delamination may also fall into the crank case, which would then requireremoval. As such, by applying the annual grooves identified herein to the non-ring travelareas, thermal spray material adheres during the spray process and mitigates contamination of the intended spray surface and the crank case. The lightly sprayed non-ring travel areas may be easily removed during subsequent honing operation.
    [57] [0057] Figure 7 illustrates a magnified, cross-sectional view of the inner surface ofcylinder bore 200. Non-travel surface 214 includes annular, square grooves 228. Travel surface 202 includes annular grooves 204 and pocket 206.
    [58] [0058] This application is related to the application having the Serial No. 13/461,160,filed I/|ay 1, 2012, and incorporated by reference in its entirety herein. This application is also, filed related to the application having the Serial No. J_,_ , and incorporated by reference in its entirety herein.
    [59] [0059] While the best mode for carrying out the invention has been described in detail,those familiar with the art to which this invention relates will recognize various alternativedesigns and embodiments for practicing the invention as defined by the following claims.Different aspects ofthe invention are also defined by the following. Aspect 1: A method ofcutting a profile in a cylinder surface 200, the method comprising simultaneously interpolatingan axial portion of the cylindrical surface using a cutting tool 300 to form a profile having aplurality of annular grooves 204, 228 and a pocket having a radius larger than the cylindricalsurface prior to the interpolating step. Aspect 2: The method of aspect 1, wherein flat peaks222, 232 are formed between adjacent grooves, and further comprising deforming each flat peak to form an undercut region 224. Aspect 3: The method of aspect 1, further comprising forming the cylindrical surface 200 by pre-boring an unhoned cylindrical surface. Aspect 4: The method of aspect 1, wherein the cylindrical surface 200 is an aluminum or magnesium alloy.Aspect 5: The method of aspect 1, wherein the cutting tool 300 includes a cylindrical cuttingbody 302 having cutting elements and mounted in a spindle. Aspect 6: The method of aspect5, wherein the simultaneously interpolating step includes rotating the cylindrical cutting body302 relative to the spindle at a rotation speed. Aspect 7: The method of aspect 6, wherein therotation speed is at least 4500 rpm. Aspect 8: The method of aspect 5, wherein thesimultaneously interpolating step includes rotating the spindle about cylindrical surface axis.Aspect 9: The method of aspect 8, wherein the rotation speed is at least 0.15 millimeters perrevolution. Aspect 10: The method of aspect 2, wherein the deforming step is carried out usinga swiping tool 600 having multiple deforming/landing surfaces. Aspect 11: The method ofaspect 10, wherein the deforming step includes rotating the swiping tool 600 at a rotationalspeed. Aspect 12: The method of aspect 10, wherein the swiping tool deforming edges havingnonzero axial helix to reduce tool deflection. Aspect 13: The method of aspect 10, wherein theswiping tool deforming edges are ground with radially staggered axial relief grooves to reducetool deflection. Aspect 14: The method of aspect 5, wherein the cutting elements include twoor more axial rows of cutting elements. Aspect 15: A method of cutting a profile in an innersurface of a cylindrical bore, the inner surface including an axial travel area and an axial non-travel area, the method comprising: interpolating the axial non-travel area using a cutting tool300 to form a profile having a plurality of annular grooves 204, 228. Aspect 16: The cylindricalbore of aspect 15, wherein the nominal diameter of the axial travel area is greater than that ofthe axial non-travel area. Aspect 17: The cylindrical bore of aspect 15, wherein the axial non-travel area includes two discontinuous axial widths ofthe cylindrical bore, and the axial travelarea extends therebetween. Aspect 18: The cylindrical bore of aspect 15, wherein the aspectratio ofthe depth of the annular grooves 204, 228 to the width of the annual grooves is 0.5 orless. Aspect 19: The method of aspect 15, wherein the plurality of annular grooves 204, 228are a plurality of rectangular annular grooves. Aspect 20: A method of cutting a profile in acylinder bore surface, the method comprising: forming a profile having a plurality of annulargrooves 204, 228 and a plurality of peaks 222, 232 therebetween; and cutting an upper portion of the plurality of annular peaks to reduce the height of the annular peaks 222, 232.
    权利要求:
    Claims (10)
    [1] 1. A method of cutting a profile in a cylinder surface (200), the method comprising: simultaneously interpolating an axial portion of the cylindrical surface using a cuttingtool (300) to form a profile having a plurality of annular grooves (204, 228) and apocket (206) having a radius larger than the cylindrical surface prior to theinterpolating step.
    [2] 2. The method of claim 1, wherein flat peaks (222, 232) are formed between adjacentgrooves, and further comprising deforming each flat peak to form an undercut region(224).
    [3] 3. The method of claim 1, further comprising forming the cylindrical surface (200) by pre-boring an unhoned cylindrical surface.
    [4] 4. The method of claim 1, wherein the cylindrical surface (200) is an aluminum ormagnesium alloy.
    [5] 5. The method of claim 1, wherein the cutting tool (300) includes a cylindrical cuttingbody (302) having cutting elements and mounted in a spindle.
    [6] 6. The method of claim 5, wherein the simultaneously interpolating step includes rotatingthe cylindrical cutting body relative to the spindle at a rotation speed.
    [7] 7. The method of claim 6, wherein the rotation speed is at least 4500 rpm.
    [8] 8. The method of claim 5, wherein the simultaneously interpolating step includes rotatingthe spindle about cylindrical surface axis.
    [9] 9. The method of claim 8, wherein the rotation speed is at least 0.15 millimeters per revolution.
    [10] 10. The method of claim 2, wherein the deforming step is carried out using a swiping tool (600) having multiple deforming surfaces.
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